Piping Cons Controller

7/30/2019 Piping Cons Controller

1/124

EnterSampleTotal ConsistencyTransmitter

TCT-2300

User ManualTCT-2301

Smart optical low consistency transmitter

BTG 2004

M2007/3en


2/124

Disclaimer

The contents of this document are subject to revision without notice due to continued progressin methodology, design, and manufacturing. BTG shall have no liability for any error ordamages of any kind resulting from the use of this document. BTG 2004.

BTG Pulp & Paper Sensors ABP.O. Box 602

SE-661 29 SffleSweden

Phone: +46 533 426 00www.btg-group.com


3/124

M2044/0en TCT-2302 Table of contents IBTG 2004

Table of contents

1 Product introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.3 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.3.1 The Peak Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.5 Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.7 Type sign explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.8 CE-declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2 Safety recommendations . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 General safety recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.2 Product specific safety recommendations . . . . . . . . . . . . . . . . . . . . . . . .14

2.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2.2 Selecting a transmitter model and assembly parts . . . . . . . . . . . . . . . . 14

2.2.3 Installing mounting details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.2.4 Installing the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2.5 Installing the electronics box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2.6 Starting up and servicing the transmitter . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1 Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.1.1 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.2 Installation and operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 183.2 Installing the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.2.1 Positioning the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.2 Probe clearance requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2.3 Sampling valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.2.4 Installing the ball valve assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.5 Mounting the probe in the valve assembly. . . . . . . . . . . . . . . . . . . . . . . 24

3.3 Installing the electronics box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.3.1 Choosing a site for the electronics box . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.3.2 Electronics box design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283.3.3 Connecting the measuring probe to the electronics box . . . . . . . . . . . . 29


4/124

II TCT-2302 Table of contents M2044/0enBTG 2004

3.3.4 External wiring dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.3.5 Main power supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.3.6 Transmitter input and output, measuring range connections. . . . . . . . . 34

3.3.7 Digital communication using the Hart-protocol . . . . . . . . . . . . . . . . . . . 34

3.4 Probe cleaning system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

3.4.1 Dimensions and installation clearance. . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4.2 Installing the PCD-1000 upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.4.3 Installing the PCD-1000 probe cleaning device . . . . . . . . . . . . . . . . . . . 40

3.4.3.1 Probe cleaning device connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4.4 Controlling the cleaning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.5 Checklist before start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.1 Starting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

4.1.1 Adjusting TAG / Serial no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.1.2 Measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.1.3 Select measuring unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.1.4 Setting measuring span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2 Clear water adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

4.2.1 At start up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.2.2 Selecting the correct mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.2.3 Adjustment of measuring gap angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

4.3.1 General remarks on calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.3.1.1 Criteria for calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.3.2 General remarks on sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.3.3 Calibration procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.3.3.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.3.3.2 Take sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.3.3.3 Load lab value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.3.3.4 Calculate calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.3.4 Multi-point calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.3.5 Calibration with given constants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.3.6 Calibration table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.3.7 Calibration curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.4 Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

4.4.1 Setting time constant (damping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.4.2 Setting alarm limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.4.3 Offset adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574.4.4 Manual loading of probe signal settings. . . . . . . . . . . . . . . . . . . . . . . . . 59


5/124

M2044/0en TCT-2302 Table of contents IIIBTG 2004

4.5 Evaluation and documentation of calibration . . . . . . . . . . . . . . . . . . . . .60

4.5.1 Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.5.2 Documenting calibrations with printer . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.5.3 Documenting calibration using the back-up card . . . . . . . . . . . . . . . . 64

4.5.4 Documenting calibration using a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.6 Electronics box display menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

4.6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.6.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.6.2.1 How to change settings and collect samples . . . . . . . . . . . . . . . . . . . . 70

4.7 Hand-held Terminal SPC-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

4.7.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.7.2 Code protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.8 Digital communication according to the Hart-protocol . . . . . . . . . . . . . .80

5 Service instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5.1 Maintenance planning and quality assurance . . . . . . . . . . . . . . . . . . . . .81

5.1.1 Inspection of the accuracy/calibration of the consistency transmitter . . 81

5.1.2 Calibration recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.1.3 Maintenance of the transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.1.4 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5.2 Service electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

5.2.1 Electronics troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5.2.2 Electronics card LED functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

5.2.3 Function and testpoints of electronics card . . . . . . . . . . . . . . . . . . . . . . 87

5.2.4 Changing the electronics card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.2.5 Change of power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.2.6 Changing the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5.2.7 Check analog out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5.2.7.1 Calibrate analog out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5.2.8 Checking communication to and from SPC-1000/A. . . . . . . . . . . . . . . . 93

5.2.9 Checking range inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5.2.9.1 Change range input using digital input (hardware) . . . . . . . . . . . . . . . . 945.2.9.2 Change range using software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5.2.10 Checking the alarm output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

5.3 Service probe and valve arrangement . . . . . . . . . . . . . . . . . . . . . . . . . .96

5.3.1 Pull out the probe from the ball valve. . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.3.2 Check clear water value and clean of probe . . . . . . . . . . . . . . . . . . . . . 97

5.3.3 Change the probe with fiber connection. . . . . . . . . . . . . . . . . . . . . . . . . 99

5.3.4 Replacing ball valve seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005.3.5 Inserting the probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101


6/124

IV TCT-2302 Table of contents M2044/0enBTG 2004

5.4 Service software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

5.4.1 Software revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.4.2 Troubleshooting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.4.2.1 Alarm & diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.4.3 Software Fault feedback SPC-1000. . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5.5 Evaluating calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

5.6 Troubleshooting, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

5.7 Maintenance of the cleaning system. . . . . . . . . . . . . . . . . . . . . . . . . . .109

6 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

6.1 Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

6.2 Valve arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

6.3 TCT-2301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

6.4 Cleaning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

6.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117


7/124

1.1 - General

M2007/3en TCT-2301 Product introduction 1BTG 2004

1 Product introduction

Total consistency transmitter

Measures total consistency, independent of varying content of filler

and fines, with a unique measuring method enables accurate

consistency measurement

Virtually insensitive to flow variations and temperature changes

for high accuracy and reproducibility

No moving parts and non-clogging probe design gives low

maintenance costs

Simple calibration and documentation provides easy start up andusage

Simple installation for low installation costs

Probe can be retracted without shutting down the process

1.1 General

The TCT-2301 is an in-line transmitter for measuring total consistency

of pulp suspensions in the range 0.01-3.5%.

Based on BTG's patented Peak Method (see section 1.3) of optical anal-ysis, the TCT-2301 is virtually insensitive to variations in filler and fines

content, making it particularly suitable for use with recycled and me-

chanical pulp suspensions.

The transmitter is mounted in-line, without any special bypass arrange-

ment, for optimized functioning of the control loop. The instrument's

unique probe, without electronic components, makes the transmitter in-

sensitive to variations in temperature and vibration. The probe is con-

nected to the wall-mounted electronics unit by an optical fiber.

An integrated fail-safe system means the probe can be installed and re-

tracted safely without shutting down the process, even in high pressure

applications.

The transmitter's non-clogging and self-cleaning features ensure trouble-

free and accurate operation with easy maintenance.


8/124

1.2 - Technical data

2 TCT-2301 Product introduction M2007/3enBTG 2004

The TCT-2301 employs modern microprocessor technology, including

fast data collection with a separate signal processor, digital data process-

ing with advanced signal analysis.

The TCT-2301 is served by the SPC-1000 hand-held terminal, which

works not only with the TCT-2301, but also with all instruments in the

BTG family of smart transmitters.

The SPC-1000 can be connected at any point on the 4-20 mA output

signal loop. Communication with a DCS is by means of a superimposeddigitized signal according to a standard Hart protocol. In addition, the

unit is prepared for fieldbus digital communication.

BTG has adopted the OPC communication standard, which enables any

OPC equipped system direct access to TCT-2301 transmitters.

1.2 Technical data

EnterSample

Terminal

Total ConsistencyTransmitter

TCT-2300

Fig 1 Smart optical low

consistency

transmitter TCT-

2301 with SPC-

1000 hand-held

terminal

Type TCT-2301 in-line smart optical consistency

transmitter for pulp slurries. One analog output fortotal consistency.

Manufacturer BTG, Sffle, Sweden

Measuring principle Light scattering using the Peak-method.

Performed by light transmission of NIR, 880 nm

Measuring range Total consistency 0.01 to max. 3.5% (0.1 - 35 g/l)

depending on fiber type and filler content

Measuring accuracy 0.004%

Repeatability 0.0001%


9/124



Process conditions

Process pressure PN 16 (232 psi at 68F)

Media temperature Max. 150C (302F)

Max. ambient

temperature

Probe: 150C (302F)

Electronics box: 50C (122F)

Process pH 4-9

Storage temperature Min. - 20C (70F)

Standardization

Standardization Quality-assured in accordance with ISO 9001.

Designed in accordance with relevant CE standards.

See section 1.8: CE-declaration of conformity

Probe

Mounting Mounted through a ball valve assembly.

Material Stainless steel to SS 2343, equiv. to ANSI 316, DIN

X5 CrNiMo 18.22, B.S.316 S16/En 58J

Connection Optical connection to electronics box.

Weight Probe 3.3 kg (7.2 lb)

Valve assembly approx. 3.8 kg (8.4 lb)


10/124



Electronics Box

Supply voltage Supply voltage 84 - 264 VAC, 50/60 Hz, max. 50 VA

- automatic setting. Output voltage 24 VDC,regulated. Output power max. 40 VA, max. constant

power 1800 mA at an ambient temperature of 50C

(122F). Approved

according to UL, CSA, VDE.

Output signal - analog 4-20 mA. Isolated against mains supply / protective

earth. Built in insulation amplifier

Current limited to 21 mA.

Loop load signal: voltage supply / load

21.6 VDC / max. 1030

24 VDC / max. 1100

26.4 VDC / max. 1270

Min. (nom.) load for communication with hand-held

terminal 250 .

Input signal - analog 0 / 4-20 mA

Output signal - digital Superimposed signal over

4-20 mA current loop according to standard HART

protocol and BELL 202 modem. Follows HART

universal commands.

Power consumption Max 600 mA incl. hand-held terminal

(excl. 200 mA) at 24 VDC

Measuring ranges(analog)

Four separate, individually programmable, externallyconnectable with binary-coded switch. Also

accessible via the communications link.

Input digital

(measuring ranges)

2 x 2 optically isolated contact inputs.

Alarm function

(digital)

Optocoupler output. Provides alarm signal on low/

high LED curr./cons.level /internal temp.

Electronic Enclosure Made of polycarbonate thermoplastic with a transpar-

ent cover. Metal-plated internally to protect against

interference.

Protection rating IP65, NEMA 4x, UL, CSA

Weight Electronics box 2.4 kg (5.3 lb)


11/124



Communications

Option 1: Using the BTG SPC-1000 handheld terminal jacked

into the electronics box. The digital communication issuperimposed over the 4-20 mA current loop.

Option 2: Directly with the DCS. See Output signal - digital.

Allows HART universal commands.

Option 3: RS-485 for connection to OPC-server. OPC program

provided by BTG. Note: Only for DCS/OCS systems

with OPC capabilities.

Option 4: Prepared for fieldbus communication e.g. Profibus or

Fieldbus Foundation.

Signal transmission 10 m (33 ft) quartz glass optic fibers included,

protected in a flexible conduit.

On request 20 (66 ft), 30 (98 ft) and 40 m (131 ft).

Accessories

Hand-held terminal, SPC-1000

See data sheet D218.55

Smart Lab Sampler, SLS-1000

See data sheet D218.62

Documentation program for PC

Probe cleaning device: PCD-1000

See data sheet D2020.

PCD-1000 cleaning device (option)

Weight 9.5kg/20.9lb including valve and probe.

Dimensions See page 2.

Ambient temp. 50C/122F

Air supply/conn. Filtered 4-7bar (58-102 psi).

6/4mm (0.236/0.157)

Water conn. Mechanically cleaned, 4-10bar (58-145 psi).

Inlet 8,5mm (0.335in)

Outlet 17mm (0.669in)

Supply voltage 24V DC supply from TCT-2301 electronics box.

Min. 4 x 0.75mm (AWG18)


12/124

1.3 - Measuring principle


1.3 Measuring principle

1.3.1 The Peak Method

The TCT-2301 employs the patented peak method for measuring total

consistency of pulp suspensions. This technology is based on the fact that

suspensions contain both large and small particles. Large particles are

typically fibers and small particles are fillers and fines.

Close study of a suspension sample shows that the high number of small

particles in the suspension remains relatively constant over time. On the

other hand, there are far fewer large particles and their number varies sig-

nificantly over time.The large particles form a relatively transparent network, within which

the small particles move freely. A narrow light beam directed through the

suspension is generally affected by both the large and small particles.

There is however an interval when only small particles affect the light

beam, and this is know as the "Peak" period.

During the other time periods, the light beam is affected by both the large

and small particles. Fig 2 and fig 3 illustrate this principle.

In fig 2, a light beam passes through the pulp flow (1). The transmitted

light is detected by a photo detector. The detector signal is amplified (5)

and then treated by the signal processor (6).

8

1

9

2

5

4

3

DC PEAK

6

7

Fig 2 Operating principle

1 Pulp flow

2 Measuring gap with light beam

3 Optical fiber from light source

4 Optical fiber to detector

5 Amplifier

6 Digital signal processor

7 Microprocessor

8 Input signals

9 Output signals

2 1 43


13/124

1.3 - Measuring principle


Three signals are computed by the detector signal: The mean value, VDC,

the peak value, VP and the AC-component, VAC. Typical time graph

showing the detector signal is displayed in fig 3.

The total consistency is obtained by adding the further treated VP and the

VDC values.

Fig 3 Output signal

VCW Clear water

VP Peak value

VDC Direct current signals

VAC Alternating current signals

TC Total Consistency

Light transmissionVolts

TC

Time


14/124

1.4 - System description


1.4 System description

The system consists of a probe (1) connected by an optical fiber to an

electronics box (2) The probe contains only optical fibers. A ball valvearrangement that is welded to the pipe system make it possible to remove

the probe without interrupting the process.

The electronics box contains electronics card, power supply, electrical

and optical connections. To set up the transmitter a hand-held terminal

(3) type SPC-1000 must first be connected (see fig 4).

The hand-held terminal allows the operator to set up and monitor the sys-

tem. It includes a liquid crystal display (LCD) with a touchscreen key-

pad.

1.5 Typical applications

Control of flotation systems or wash stages for de-inking of

recycled fibers

Control of screening and cyclone cleaning processes

Monitoring of TMP/CTMP steam and hot-water recovery

systems

CRC

1

3

5

2

8

49

7

6

EnterSample

Terminal


TCT-2300

Fig 4 Typical control loop for

consistency control of the TCT-

2301

1 Measuring probe

2 Electronics box

3 Hand-held terminal SPC-1000

4 3/4 wire system for analog output

5 Controller/recorder (DCS)

6 Dilution water valve

7 Pulp chest with sufficient mixing

8 Stock pump

9 BTG sampling valve type MPS-1000


15/124

1.6 - Dimensions


1.6 Dimensions

30012"

46918.5"

53

2.

1"

121

4.

8"

121

4.

8" 50

2

251

9.

9"

108

4.

3"

Min 1004"

Fig 5 TCT-2301 Dimensions

1 Electronics box

2 Probe with retraction

system

1

2


16/124

1.7 - Type sign explanations


1.7 Type sign explanations

1. Manufacturer

2. CE-marking

The TCT-2301 is approved according to CE directives.

3. CSA-marking

The TCT-2301 electronics box is approved according to Australian C-TIC N1619 directives.

4. ETL-marking

The TCT-2301 electronics box is approved by ETL

5. Warning sign

The device is designed for industrial use. Installation, handling and ser-

vice must only be carried out by trained and authorized personnel and ac-

cording to relevant standards. Read the manual for detailed information

and pay special attention to the warning signs!

BTG Pulp & Paper SensorsABBox 602661 29 SffleSWEDEN

N1619

TYPE

www.btg-group.com

VOLTAGE

APPARENT POWER

NO

FREQUENCY

INSTALLATION CATEGORY FACTORY IDENTIFICATION

Fig 6 Type sign

1 Manufacturer

2 CE-marking

3 C-TIC marking

4 ETL-marking

5 Warning sign

6 Type specification

7 Voltage

8 Apparent power

9 Installation category

10 Frequency

11 Manufacturing number

12 Factory Identification

1 2 3 4

6

7

8

5

9 10 11 12

TCT-2301

100-240 VAC 50-60 Hz

50 W III

Always refer to the typesign when ordering spareparts.


17/124

1.7 - Type sign explanations


6. Type specification

7. Voltage

Automatically adjustable between 100-240V AC.

8. Apparent power

According to CE directive. Max. continuous output.

9. Installation category

According to CE directive. Resistant to transients.

10.Frequency

The unit operates both 50 and 60 Hz.

11.Manufacturing number

BTG internal product identification number.

12.Factory identification


18/124

1.8 - CE-declaration of conformity


1.8 CE-declaration of conformity

CE-Declaration of Conformity

According to EN 45014

Manufacturers Name BTG Pulp & Paper Sensors ABManufacturers Address P.O. Box 602 S- 661 29 SFFLE, Sweden

declares that the product:Product Name Total Consistency TransmitterModel Number TCT-2300/2301/2302/with FCI-1000complies with the amendments andrequirements of the: Machinery Directive 89/392/EEC

Low Voltage Directive 73/23/EECEMC Directive 89/336/EECPED Directive 97/23/EEC

and conforms with the following productstandards and PED conformity assessment

procedureSafety EN 292/1-2LVD EN 61010-1

PED Pressure equipment for piping.

In accordance to Article 1,Table 9, art.3 (3), Annex II(Sound eng. practise)Must not bear CE-marking

EMC EN 50081-2 Aug.93EN 61000-6-2 Apr.02

Quality System ISO 9001monitored byLloyd`s Register Quality Assurance

SffleMars 2002

Tom Gustavsson, MD


19/124

2.1 - General safety recommendations

M2007/3en TCT-2301 Safety recommendations 13BTG 2004

2 Safety recommendations

2.1 General safety recommendations

Installation, handling and service must only be carried out by trained and

authorized personnel and according to valid standards.

The product is designed for industrial use.

Installation category: III

Shock protection: Class I

Pollution degree: 2

IP Code: IP65 / NEMA 4X

The product complies with the EEC directives and relevant

standards:

To meet the EMC directive the following precautions have to betaken:

1. All wiring has to be shielded.

Power supply electronics: shielded, coverage 80%Interface cable: coverage 100% aluminum

2. All units are tested as a complete system to conform with rele-vant CE directives and their standards.

When using the unit in other combinations, BTG cannot guaranteethe CE directive conformity.

The unit in combination with customer installed external devicesmay conform with EMC and safety requirements when properlyinstalled and using an adequate CE marked equipment.

The system operator is responsible for the CE directive conformi-ty. Conformity must be checked by inspection.

Take precautions when handling equipment in pressurized/hot lines.

See section 1.2: Technicaldata for detailedinformation.


20/124

2.2 - Product specific safety recommendations

14 TCT-2301 Safety recommendations M2007/3enBTG 2004

2.2 Product specific safety recommendations

These safety recommendations are based on a risk analysis carried out in

accordance with the requirements of the machinery and low voltage di-

rective in order to comply with European standards for CE marking.

2.2.1 General

The possibility of risk from a consistency transmitter in operation only

arises when covers have been removed during installation and servicing,

due to hazardous electrical voltage.

Read these safety recommendations before installing the transmitter.

Follow the recommendations when installing the transmitter, starting upand servicing. Use warning signs for safety information!

These safety recommendations apply to the transmitter fitted with an AC

powered electronics box. Mounting parts, such as the weld-in studs, are

dealt with in accordance with the pressure vessel standards of the respec-

tive countries.

! For good personal and functional safety: Use only parts which

have been manufactured or approved by BTG.

2.2.2 Selecting a transmitter model and assemblyparts

Pressurized parts must be suited to the current maximum pipe pressure in

relation to temperature. Select a material for the parts that are in contact

with the medium so that corrosion does not occur.

2.2.3 Installing mounting details

Welding and subsequent inspection should take place in accordance with

current standards and regulations.

2.2.4 Installing the transmitter

Construct a platform or use safe and approved ladders if the

transmitter is located high up. This platform will make it easier to fit

and start-up the transmitter and carry out service in the future.

The rubber quality of the transmitter seal (O-ring) should be selected

to suit the current medium. The O-ring supplied is suitable for this

application.

Screw the valve assembly firmly onto the weld-in stud.

Be sure that the pipe isempty before opening it!


21/124


M2007/3en TCT-2301 Safety recommendations 15BTG 2004

Install the probe into the valve assembly. Fit the two screws locking

the probe in place. Check that these screws are properly tightened, as

well as the four screws holding the valve together. See section 3.2.5:

Mounting the probe in the valve assembly for details.

When the probe has been installed, carry out test pressurization using

water in the pipeline. The correct test pressure depends on standards

and regulations in each country. In some lines for which inspection

is required, a pressure test must be carried out before the product can

be commissioned.

2.2.5 Installing the electronics box

A hazardous voltage is used to drive the electronics box. The electronics

box may only be connected by a qualified electrician in accordance with

instructions. The earth ground should be connected correctly and

checked.

It should be possible to switch off the voltage in the distribution centre,

for example. A clear warning, such as a sign, should let other people

know that work is in progress and the switch must not be touched.

Use only metallic cable fittings with shield connection for the

electronics box.

2.2.6 Starting up and servicing the transmitter

Read through the following points before starting up and servicing the

transmitter. Bear also in mind that the points mentioned above contain

important information for these operations.

Before removing the probe from the valve assembly, check carefully

that the valve is closed. Hot or corrosive liquid flowing out under

pressure may cause serious chemical burn injuries!

Take care when opening the cover of the electronics box with built-

in power supply unit. It contains live parts that may cause electric

shocks. Live parts are protected against normal contact provided that

connections are made correctly.

When the probe is exposed to dangerous basic or acidic corrosive

media, it should be removed from the pipeline regularly for

inspection. Replace any damaged seals. If the probes pressurized

parts have corroded, check that the material is correct for the

application. Leakage may cause personal injury or damage to

equipment due to corrosion or burning!

Check that the screws/nutholding the valve/probetogether are mounted andproperly tightened.

DANGER!High voltage inside theelectronics box.Connections may only becarried out by qualifiedpersonnel.

To prevent electrical shock connect the protectiveearth PE properly.


22/124


16 TCT-2301 Safety recommendations M2007/3enBTG 2004


23/124

3.1 - Before you start

M2007/3en TCT-2301 Installation instructions 17BTG 2004

3 Installation instructions

3.1 Before you start

This section contains instructions for planning and implementing the in-

stallation of the BTG TCT-2301 in-line consistency transmitter.

If you are in doubt whether the model you plan to install is the same

in all respects as the model described in this manual, or you have any

questions about installation, please contact your BTG sales engineer.

When you are satisfied that your TCT-2301 has been correctly installed

and are ready to power up the system for calibration, please turn to sec-

tion 3.5: Checklist before start.Double checkitems in the list before powering up. This list can help en-

sure a trouble-free initialization of your system.

This section introduces the essential components of the system.

This introductory section is followed by:

section 3.2:Installing the transmitter

This section contains detailed instructions for installing the trans-mitter.

section 3.3:Installing the electronics box

This section describes how to connect mains power supply, inputsand outputs.

section 3.4:Probe cleaning system (option)

This section describes how to install the PCD-1000.

section 3.5: Checklist before start

When you are satisfied that your TCT-2301 has been correctly in-stalled and are ready to power up the system for calibration, pleaseturn to this section.


24/124

3.1 - Before you start

18 TCT-2301 Installation instructions M2007/3enBTG 2004

3.1.1 Visual inspection

This product was inspected and tested prior to shipment. However, even the

best products can sustain shipping damage that will only be seen if theproduct is inspected. Before proceeding check the probe assembly, the

hand-held terminal, and the electronics box for shipping damage. Look

for loose screws, wires or electronic components.

3.1.2 Installation and operating conditions

The Consistency Transmitter is a precision tool and must be properly in-

stalled to ensure reliable service. Please, read the following instructions

and user information before installing the transmitter.

The transmitter is manufactured to provide accurate and reliable mea-surements over a long period of time.

! Correct installation will ensure maximum operating life of thetransmitter.

For safety precautionsplease refer to section 2.Product type signexplanations see section 1.7


25/124

3.2 - Installing the transmitter


3.2 Installing the transmitter

3.2.1 Positioning the transmitterTo make an accurate and reliable measurement it is critical to find the correct

installation point.

Fig 4 on page 8 shows a typical installation. Your BTG sales engineer

can help you select the location that will give the best results in relation

to your control strategy.

! Minimum recommended flow velocity: 1 m/s (3.3 ft/s).

! To minimize time lag, locate the probe close to the dilution point.

Warning: To avoid

personnel injuries, burninginjuries, aggressivechemical injuries etc., it isextremely important thatthe pipe is depressurizedand empty before openingit for installation orremoval of the equipment.

Fig 7 Recommended

distance between

pump and consistency

transmitter.

Can also be placed inthe cone after the

pump. Turbulent flow

will give the best

measuring conditions

for this type of

transmitter.

0.1

m

(4in)

Fig 8 Installation of the

probe in relation to

different pumps


26/124



Important recommendations:

1. Do not install the probe where there is trapped air or where air may

be sucked into the process.

2. If there is risk of flocculation in the pulp suspension, install the probe

where the flow rates exceeds 1 m/s (3.3 ft/sec).

This applies particularly to long-fiber pulp suspensions.

3. Install the probe so that it is protected from direct mechanical dam-

age.

4. Protect the probe from heavy vibration such as cavitation or unbal-

anced pumps. One method is to install a rubber bellows in the line.

A B C

0

90

0

F low

Direction

TCT-2300


probe near a pipe

elbow

! Alternative A is the

most suitable. Avoidalternative C.


27/124



If the probe is installed in a horizontal pipe, always install it at the side

of the pipe rather than at the top or bottom to avoid problems with

trapped air or dirt. Remember the clearance requirements, so that the

probe can be mounted in the ball valve arrangement.

5. The ball valve assembly should be mounted at a 90 angle to the pipe

line.

6. The ball valve assembly should be mounted on the side of the pipe

line. A small angle downwards makes it possible for the pulp to evac-

uate when the probe is retracted and also makes the insertion of the

probe easier. See fig 10 below.


probe in a horizontal

pipe.


28/124



3.2.2 Probe clearance requirements

The installed length of the probe, inserted into the ball valve arrange-

ment, is approximately 470 mm (18.5 in) long. You will also need a min-imum distance of 300 mm (11.8 in) to remove the probe from the pulp

line. Leave sufficient room around the probe to perform this task.

The probe weighs approximately 3.3 kg (7.2 lbs).

! Remember to provide access room for an operator, as well as thefull depth of the probe assembly and the electronics box.

3.2.3 Sampling valve

The sampling valve should be installed close to the transmitter. This

helps to ensure that the laboratory sample is representative of the sample

measured by the transmitter.

Installing an appropriate BTG sampling valve, will ensure reliable re-

sults.

! Install the sampling valve up or downstream of the transmitter butnot closer than 0.5 m (1.5 ft) to the transmitter to avoid

disturbances.

30012"

46918.5"

5

3

2

.1"

121

4.

8"

121

4.

8" 50

2

25

1

9.

9"

108

4.

3"

Min 1004"

Fig 11 Probe. Dimensions in

mm/in


29/124



3.2.4 Installing the ball valve assembly

1. Mark the position on the pipe wall where the probe is to be located.

2. Drill a 50 mm / 2 inch hole in the pipe at the marked position.

3. Adapt the welded stud profile to the pipe. Adjust length according to

fig 12.

4. Make sure the weld-in stud is aligned to the pipe. See fig 12.

5. Weld the stud to the pipe. A full penetration weld must be used.

! If the probe is delivered with a PCD-1000, refer to section 3.4: Probecleaning system (option).

6. Mount the ball valve arrangement. The slot for the crank handle mustbe located upwards since there is a scale on the probe that must be

adjusted before the probe is mounted.

Fig 12 Mounting the flanged

weld-in stud

Fig 13 Mounting positions of

the probe.


30/124



3.2.5 Mounting the probe in the valve assembly

1. Make sure the measuring gap on the probe is at a 45 angle to the

pulp flow. The angle may have to be changed after start-up.

If the angle is not correct, loosen the three screws that hold the probe

flange and adjust the probe so that the punch mark on the probe is at

the 45 line on the scale. Tighten the three screws properly. A suit-

able allen key is included in the delivery.

! Angles other than 45 can be used in some installations. Seesection 4.2.3:Adjustment of measuring gap angle.

45

2

2

1

45

2d

2c

1

0

90

45

45

0

TCT-

23

00

2b

2a

1

0

90

45

45

0

TCT-

23

00

Fig 14 Measuring gap angle

adjustment

1 Punch mark

2 Pulp flow direction

Fig 15 Probe scale

adjustment


31/124



2. Apply a small amount of o-ring lubricant to the o-ring in the ball

valve housing.

3. Make sure the o-ring on the probe flange is mounted.4. Insert the probe, using a twisting motion to get the probe tip to enter

the o-ring. Place the flexible insertion screw in the correct position

and make sure the hook with its locking device is in the correct po-

sition and secured.

5. Open the ball valve and insert the probe by cranking the handle.

6. Secure the probe in inserted position with the two security screws

! Secure the two security screws properly

7. When removing the probe, reverse the above procedures.

Fig 16 Mounting the probe in

the valve assembly

Avoid getting O-ringlubricant on the measuringgap


32/124

3.3 - Installing the electronics box


3.3 Installing the electronics box

3.3.1 Choosing a site for the electronics box

! Locate the electronics box close to the transmitter/ sampling valve

to achieve a correct and convenient connection of the SPC-1000

hand-held terminal for calibration and monitoring.

The hand terminal SPC-1000 can be positioned in a holder, located close

to the electronics box. See fig 20.

Install the box in a position where it will be protected from mechanical

damage.

Fig 17 Dimensions of the

electronics box

Fig 18 Electronics boxclearances

50

2"

300

12"

50

2"

200

8"

EnterSample

Terminal


33/124



BTG recommends that a roof or overhang is located above the electronics

box to protect it against spray and pulp. If the box is located outdoors a

roof will protect the unit from direct sunlight which can cause excessive

operating temperatures. If possible, the SPC-1000 mounted in its holdershould also be protected.

The electronics box is equipped with three attachment lugs and should be

bolted to a wall.

200

8"

300

12"

75

Fig 19 Protecting roof for

Electronics box

Fig 20 Wall mounted

brackets positioning

the SPC-1000, for

easier operation

Fig 21 SPC-1000 positioned

in the brackets


34/124



3.3.2 Electronics box design

! Electronics boxes manufactured by BTG are designed to meet

personal safety and interference requirements under the EuropeanCE directive and Canadian CSA requirements.

The plastic enclosures are made of polycarbonate thermoplastic.They are metal-plated internally to protect against interference.

Metal screw caps for attaching connection cable shield are an im-portant part of the interference suppression system.

The electronics box is supplied with an external jack connectionfor the hand terminal, SPC-1000/A, and the Smart Lab Sampler,SLS-1000.

Terminal

Total Consistency

Transmitter

TCT-2300

1.30% 12.53mA

Sample Enter

+ALARM-

F3

F2

F1

+24 GND +AOUT1- +AOUT2- IN1 IN2 GND +AIN-N L PE

ALARM

M

ODE

PW

ROK

DO1

DO2

Di1

IN

1

IN

2

GND A B

COM+DO1DO2DI1 GND A B

6

8

Fig 22 Electronics box

1 Display

2 Operating buttons

3 SPC-1000/A

connection

4 LEDs

5 Power switch

6 Fuses

7 Electrical connections

8 Optical fiber connection

3

4

5

2

1

7


35/124



3.3.3 Connecting the measuring probe to the

electronics box

The optical connection is on the lower right side of the electronics box.Remove the protective cover on the electronics box connector, and on the

optical connector on the probe. Note the position for the optical connec-

tor in fig 23. The connector fits only in one position. Make sure the O-

ring is mounted on the probe connector. Push the connector all the way

in. Try to turn the connector (this should not be possible) to verify that it

is in the end position. Secure the connection properly with the plastic nut.

Coil the extra optical fiber and secure it under the electronics box in order

to avoid the risk of mechanical damage.

! Make sure the optical connector from the probe is positioned

correctly and pushed all the way in before securing it with theplastic nut.

! The optical fiber must not be coiled with a radius smaller than50mm (2 in) Locate it so that is protected and not subject to risk of

mechanical damage.

The standard optical fiber is 10 m (33 ft). It is possible to use optical fiber

up to 40 m (131 ft) long. Contact your BTG sales engineer for more in-

formation regarding optional fiber lengths.

! Do not cut the optical fiber.

Fig 23 Optical connection

1 Aluminum washer

2 Electronics box

3 Rubber sealing

4 Electronics box optical

connector

5 O-ring

6 Plastic nut

7 Probe optical connector8 Optical fiber to probe


36/124



3.3.4 External wiring dimensions

BTG recommends properly dimensioned wire, shielded and twisted in

pairs, for connection between the electronics box and external equip-ment. See also section 2.1: General safety recommendations.

Power supply cable:

Electronics box with built-in power supply unit:

Shielded (80%)

3 x 0.75 mm2 (3 x AWG18) with PE.

Cable diameter: 7,5-13 mm

In accordance with the IEC 227/245 standard

Output signal cables:

Shielded (80%), twisted pair

Min. 2 x 0.3 mm2 (2 x AWG24).

The size typically used is 2 x 0.75 mm2 (2 x AWG18)

Cable diameter: 6-11 mm

Range select cable:


Min. 2 x 0.3 + 2 x 0.3 mm2 (2 x AWG24 + 2 x AWG24)


Alarm/AUX-in cable:


Min. 2 x 0.3 mm2 (2 x AWG24)


! Signal cables can be combined to one or two cables.


37/124



3.3.5 Main power supply connections

Important: Before installation, ensure that:

1. All power to the system has been turned off.

2. The 2AT fuses on the main card, marked F2 and F3, are in-

stalled.

The conduit for the power supply to the electronics box should beinstalled in the leftmost hole.

Wiring the main power supply screw terminal:

The earth wire must be connected to the terminal indicated by theprotective earth symbol PE.

See fig 26 on page 32.

3. Strip the cable covering (insulation) to expose the shortest pos-

sible length of the connection wires.

! Unshielded long, looped wires may cause interference! This can

interfere with the signal!

4. Once the wires are inserted, tighten the screws to secure them.

Mount the connector in its position.

5. To ensure interference-free operation a shielded cable should be

used. Make sure the shield is correctly connected - fig 24.

6. Turn on the main power supply.

DANGER!High voltage within theelectronics box.Connections may only becarried out by qualifiedpersonnel

To prevent electrical shock- connect the protectiveearth properly PE

Fig 24 Connection of cable

shield, in special cable

screw cap (metal)

1 Connection cable for power

supply, measuring range

etc.

2 Nut

3 Sealing ring

4 Insert ring

5 Cable shield

6 Socket

7 Free wires

! Tighten nut fully for

maximum contact for

the shield.

1

3

6

7

2

5

4


38/124



7. Switch on the main power on the electronics card. The power

LED should now light up. See fig 25. If not, check first the con-

nections and then the 2 AT fuse for the power supply located in-

side the electronics box.

Check the 24 V DC at terminal +24, GND - fig 26.

Notes on fig 26:

An external 2-pole switch close to the electronics box is required.

Standard output signal 4-20 mA with superimposed digital signal

according to Hart-protocol. See section 3.3.7.

Four different measuring ranges (RANGE 1-4) are available. The

setting of the respective measuring range is arranged via a binary

code switch (range setting - see fig 26 switch A/B) or DCS.

The unit is prepared for fieldbus. To access the communication anadditional circuit card is required.

Terminal

Total Consistency

Transmitter

TCT-2300

Sample Enter

+ALARM-

F3

F2

F1

+24 GND +AOUT1- +AOUT2- IN1 IN2 GND +AIN-N L PE

ALARM

MODE

PWROK

DO1

DO2

Di1

IN1

IN2

GND A B

COM+DO1DO2DI1 GND A B

Fig 25 Power connections

electronics box

1 Fuses2 Power connection

100-240 V AC

3 Power switch

4 24 VDC out

4-20mA output signals

Range setting

0-20 mA input signals

Alarm

5 LEDs

6 Digital signals

7 Fieldbus

8 RS-485

9 Optical fiber connection

10 SPC-1000/A

connection

52 31 104 6 7 8 9

OUT14-2

0mAmin250ohm

TCT

-230

1

S = Shield connected to cable-gland* = Not used for TCT-2301

PELN +24V

RangeA

GND + - + - IN1

RangeB

GND

Line power100-240 VAC

RS485I N 2 G N D

AOUT 1 AOUT 2

+ - + -

AIN ALARM

Power

to

external

equipment

AOut

1

AOut

2*

AuxIn

Alarm

COM

+D O1 D O2 D I1

S S

A B

GND

Field bus

A B

PCD

-1000option

PCD

-1000option

A BRANGE 1 0 0RANGE 2 1 0RANGE 3 0 1RANGE 4 1 1

0=

1=

Fig 26 Wiring diagram for

electronics box

TCT-2301


39/124



Explanation for fig 26 TCT-2301 wiring diagrams.

! To enable communication using the Hart-protocol, and use of ahand-held terminal, a 250 min. circuit resistance is required.

A 250 resistor is connected at terminals A OUT+ and A OUT- atthe factory.

Remove the resistor when connecting the output signal.

Terminal Function

N Neutral

L Phase 85-264 V AC, 47-440 Hz, power fuse 2AT

PE, Protective earth

+24 +24V DC (to optional PCD-1000)

GND Ground, 0V DC (to optional PCD-1000)

AOUT 1+ Output signal 4-20mA

AOUT 1- Output signal 4-20mA

AOUT 2+ Not used

AOUT 2- Not used

IN1 Range A for external range setting

IN2 Range B for external range setting

GND Ground, Common for range A and B

AIN+ Input signal 0-20mA (from external equipment)

AIN- Input signal 0-20mA (from external equipment)

ALARM+ Alarm from TCT

ALARM- Alarm from TCT

COM + Common (to optional PCD-1000)

DO 1 Digital output signal 1(to optional PCD-1000)

DO 2 Digital output signal 2

DI 1 Digital input signal 1

RS-485 GND Ground

RS-485 A Serial connection

RS-485 B Serial connection

Fieldbus GND Ground

Fieldbus A Fieldbus connection

Fieldbus B Fieldbus connection


40/124



3.3.6 Transmitter input and output, measuring

range connections

Important: Before installation, ensure that:

1. The mains power supply is connected according to section

3.3.5.

2. The mains power is turned OFF.

3. To ensure interference-free operation, the cable fittings should

be adapted for shielded cables. See fig 24 on page 31.

Wiring the signal screw terminals:

The screw terminals are in the lower section of the connection terminal

fig 25 on page 32.

4. Strip the cable covering so the shield is exposed. Use the shortest

possible length of the connection wires.

! Unshielded long, looped wires may cause signal interference! Strip

only enough insulation from the wires to insert them. The wires areconnected according to fig 26 on page 32. Once the wires are

inserted, tighten the screws to secure them.

5. Tighten the nut fully to ensure a good contact for the shield.

6. Turn on the power and test the functionality.

3.3.7 Digital communication using the Hart-

protocol

Certain functions are available as a digital signal under the Hart-proto-

col and BELL 202 modem standard.

! The transmitter complies to Hart-protocol standard requirements.

A BTG handheld terminal is used to set and calibrate thetransmitter. As this unit provides additional functions not covered

by the Hart-protocol, a standard Hartcompetitive terminal offersonly limited functionality.

Communication takes place as a superimposed signal over the 4-20 mA

output signal loop.

! For details, please contact the Hart Communication Foundation or

BTG.

To ensure disturbance-freeoperation it is essentialthat cable shields arecorrectly connected in thecable screw caps - see fig24.


41/124

3.4 - Probe cleaning system (option)


3.4 Probe cleaning system (option)

This section describes how to install the PCD-1000 probe cleaning de-

vice. The system can be delivered as a separate unit for rebuilding exist-

ing units or together with a complete TCT-2301 transmitter. If the

cleaning system is ordered with the TCT-2301 the probe will be mounted

in the cleaning device at the BTG factory. The installation method is de-

scribed for both cases.

3.4.1 Dimensions and installation clearanceEnsure that there is sufficient clearance to remove the probe and cleaning

device from the valve assembly.

The installed device is approx. 700 mm (28 in) long. You will need at

least 300 mm (12 in) to remove the device from the valve arrangement.

The cleaning device weighs approx. 9.5 kg (21 lbs) including the TCT-2301 probe.

Fig 27 PCD-1000 probe

cleaning device

140

5,5

"

~550

22"

Min 100

4"

700

28"

Min 300

12"

92

3,6

133

5,3

"

Fig 28 PCD-1000 dimensions


42/124



3.4.2 Installing the PCD-1000 upgrade kit

This section describes how to upgrade an existing TCT-2301 transmitter

with the probe cleaning device PCD-1000/A (accessory).

! Make sure the pipe is empty and pressureless before starting the

installation.

1. Remove the TCT-2301 probe from the existing valve arrangement,

note the measuring angle, that is, the measuring gap angle in relation

to the pulp flow.

2. Disconnect the optical connection from the TCT-2301 electronics

box. Protect the optical connection with a plastic tube or similar.

3. Remove the handle and the flange with the angle scale.

4. Place the cleaning device on a workbench with the valve facing

downwards.

! To keep all O-rings in position during disassembly/assembly,

always place the cleaning device in a upright position with thevalve facing downwards.

5. Unscrew and remove the screw (2) and the nut (1).

6. Unscrew and remove the nuts (4) and the washers (5).

7. Loosen the air tube (9) from the nipple and remove the rear cylinder

flanged end (6) together with the protective sleeve (3).

Keep track of the O-rings (7 and 8).

21

20

Fig 29 Sequence of installing

the PCD-1000

upgrade kit

235 4678

9

1


43/124



8. Remove cylinder flanged end (12) and pull out piston with guiding

rod (13). Keep track of O-ring (11) and guide ring (10).

Alternatively, pull out the cylinder flanged end and piston in one

piece and separate them afterwards.

9. Remove the rubber bushing (14) from the guiding rod.

10. Loosen the screws (16) and separate the piston (15) and guiding rod

(17) from each other.

11. Insert the probe (18) in the piston (15) and the fiber cable in the guid-

ing rod (17).

12. Make sure that the screw hole on the edge of the guiding rod is

aligned with the measuring gap on the probe. Then join the piston

and the guiding rod with the screws (16). Do not forget the O-rings

(19).

13. Put the accompanying rubber bushing (14) over the fiber cable and

push it into the tip of the guiding rod.

1210 11 13 14

1615 17

18 19 19 17


44/124



14. Push the probe and piston into the cylinder. Make sure the guide ring

(10) is in position.

15. Mount the cylinder flanged end (12), the rear cylinder flanged end

(6), and the protective sleeve (3), to the cylinder.

Make sure that the O-rings (7, 8, and 11) are in their proper positions,

and that the nipple (21) on the rear cylinder flanged end are posi-

tioned on the same side of the cylinder as the nipple (20) on the frontcylinder flanged end. The parts must be pulled over the optic cable.

16. Mount the nuts (4) and washers (5), but do not tighten them fully.

17. Connect the air tube (9) to the nipple (21) on the rear cylinder flanged

end.

18. Loosen the screws (24) and turn the protective sleeve until the screw

hole on the guiding rod is visible through the slot (25).

2120

24 2522 23

26


45/124



19. Connect the protective sleeve to the guiding rod with the screw (1)

and nut (2).

The slot on the protective sleeve is now aligned with the measuring

gap.

20. Turn the probe, by turning the protective sleeve, until the measuring

gap is pointing 45 towards the pulp flow. Use the angle scale on the

rear cylinder flanged end for assistance.

21. Tighten the screws (24) to fasten the protective sleeve and to fix the

angle of the probe.

22. Loosen the screws (23).

23. Turn the flushing valve (26) so that the inlet faces the measuring gap

of the probe. The air cylinder shall at this stage have its quadratic ex-ternal cross section turned the same way as the flanged ends of the

ball valve.

24. Tighten the screws (23) and the nuts (5).

25. If the existing TCT-2301 is mounted with a threaded weld-in stud be-

tween the ball valve assembly and pipe, the new flanged weld-in stud

(22) must be used.

Weld the new flanged weld-in stud to the pipe in a new position ac-

cording to section 3.2.4.

Plug the old weld-in stud with a blind flange (accessory).

26. If the existing TCT-2301 is mounted with a flanged weld-in stud, re-

move the delivered weld-in stud from the cleaning device and mount

the PCD-1000 to the existing flanged weld-in stud.

If the transmitter is submitted to vibration we recommend using rein-

forcement. See fig 28 on page 35.

Fig 30 Mounting the weld-in

stud

The threaded weld-in studis not dimensioned to holdthe PCD-1000


46/124



3.4.3 Installing the PCD-1000 probe cleaning

device

This section describes how to install the probe cleaning devicePCD-1000/A that is delivered with a TCT-2301 probe. (Option)

! Make sure the pipe is empty and pressureless before starting theinstallation

1. Loosen the screws (3) that holds the protective sleeve (4) fixed.

2. Loosen the nuts (2).

3. Turn the probe, by turning the protective sleeve, until the measuring

gap is at a 45 angle to the pulp flow. The slot (3) on the protective

sleeve is aligned with the measuring gap. Use the angle scale on the

rear cylinder flanged end for assistance.

4. Tighten the screws (3) to fasten the protective sleeve (4) and to fix

the angle of the probe.

5. Loosen the screws (1).

6. Turn the flushing valve (6) so that the inlet faces the measuring gap

of the probe. The air cylinder shall at this stage have its quadratic ex-

ternal cross section turned the same way as the flanged ends of the

ball valve.

7. Tighten the screws (1) and nuts (2).

8. Remove the flanged weld-in stud from the cleaning device and weld

the flanged weld-in stud to the pipe, according to section 3.2.4.

9. Remount the PCD-1000 to the flanged weld-in stud.

43 521

6

Fig 31 Mounting the weld instud


47/124



If the transmitter is submitted to vibration we recommend using rein-

forcement. See fig 28 on page 35.

3.4.3.1 Probe cleaning device connections

Three connections are needed to make the cleaning device operational.

Connection requirement:

Water: Use standard water quality.

Air: 4-8 bar (58-100psi) or at least half the process pressure.

1. Connect water to the membrane valve. The connection is 8.5mm

(0.33 in)

2. Connect air to the solenoid valve by 6/4 (1/4 in) hose.

3. Connect the control signal and 24V DC supply from the TCT-2301electronics box. See section 3.3.5:Main power supply connections.

3.4.4 Controlling the cleaning device

All settings to control the cleaning device are made from the TCT-2301

electronics box. Instructions can be found in section 4.6.2.1:How tochange settings and collect samples.

Fig 32 Cleaning device

connections Water inlet

Water outlet

Control signals

and 24 V DC from

TCT-2301

electronics unit

POWER

VALVE

VALVE

VALVE

DO1

+COM

GND

+24V

Air connection


48/124

3.5 - Checklist before start


3.5 Checklist before start

When you are confident that your TCT-2301 has been correctly installed,

and are ready to power up the system for calibration and/or testing, run

through this brief check list before powering up. Using this list will help

ensure trouble-free initialization of your system.

1. Make a clear water adjustment before installing the probe in the

ball-valve arrangement. See TCT-2301 operating instructions,

section 4.2.

2. Check that the measuring gap on the probe is at the correct angle

to the pulp flow.

3. Check that the transmitter is fully inserted and the two security

screws are properly tightened.

4. Ensure that the optical fiber is protected from mechanical dam-

age, and attached securely to the transmitter.

5. Check all wiring.

6. Switch on the mains power supply.

7. Connect the hand-held terminal to the electronics box. Switch it

on and check that the display lights up.

Proceed to the TCT-2301 Operation instructions.


49/124

4.1 - Starting the transmitter

M2007/3en TCT-2301 Operating instructions 43BTG 2004

4 Operating instructions

4.1 Starting the transmitter

All settings are made from the hand-terminal, SPC-1000, or from the

electronics box.

This chapter describes the handling of the transmitter and its possibilities

All functions can be accessed from the hand-terminal, while the display

on the electronics box only provides certain functions, see description in

section 4.6:Electronics box display menu.Before getting started, the transmitter must be installed in the pulp line,

the electronics box wired electrically and connected, and the power

switched on according to section 3:Installation instructions.

The hand-terminal, SPC-1000, is very easy to handle. It is equipped with

a touch-screen with buttons to make selections and settings. See section

4.7:Hand-held Terminal SPC-1000 for further information.

Connect the SPC-1000 to the front of the electronics box. Switch on the

hand-terminal.

Select from the menu.

Before making any changes, always read all transmitter data .

Should a failure message appear on the screen, see section 5.4.3: Soft-

ware Fault feedback SPC-1000 for action, if necessary.

All changes made must be downloaded to the transmitter to take effect.

Use . This function can be password protected. See section

4.7.2: Code protection.

EnterSample

Terminal


TCT-2300Fig 33 TCT-2301 consistency transmitter

with electronics box and hand

terminal

TCT2301v1.x

4-20mA MODEMPRINTER PWR EJECTON/OFF MEMORY CARD

SPC-1000Communication Terminal

Sensor:Select program below.

Backup:First select program below and thenrestart with backup card.

TCT2300v1.x

TCT2300v1.x

TCT2300v1.x

TCT2300v1.x

TCT2300v1.x

TCT2300v1.x

TCT2300v1.x

TCT2300v1.xTCT

2301v1.x

Readdata

Senddata


50/124


44 TCT-2301 Operating instructions M2007/3enBTG 2004

4.1.1 Adjusting TAG / Serial no.

The TAG is the transmitter identification name in the process. Maximum

8 identification characters can be entered (letters and/or digits).

The setting is done using followed by .

Enter the required TAG. The buttons have several characters, select the

correct one by pressing several times, wait two seconds and the cursor

will jump to the next position.

4.1.2 Measuring range

The transmitter can handle four different measuring ranges and calibra-tions. Different ranges make it possible to have different calibrations for

different qualities and conditions in the process.

Connection of different ranges is done via binary inputs, see section

3.3.6: Transmitter input and output, measuring range connections.

Range 1 is always active if nothing is connected to the binary inputs.

Make sure changes are made in correct range, select using .

The active range is shown on the main menu, lower right Range: X

Confi-gure

Tag.no

25NT1237



Readdata

EditRange1

Confi-gure

Cali-brate

4 mA1.00%

20 mA3.00%

Damp1s

Offset0.00%

Misc. Print

Note ! Trend

Calib-rationcurve

Senddata

Tag: 25NT1237 Range 1

---------------0% 53.3% 100%

Cons. 1.30% TCT-2301

Confi-gure

Tag: 25NT1237 Range x

---------------0% 53.3% 100%

Cons. 1.30% TCT-2301



Readdata

EditRangex

Confi-gure

Cali-brate

4 mA1.00%

20 mA3.00%

Damp1s

Offset0.00%

Misc. Print

Note ! Trend

Calib-rationcurve

Senddata

EditRangeX


---------------0% 53.3% 100%

Cons. 1.30% TCT-2301


---------------0% 53.3% 100%

Cons. 1.30% TCT-2301TCT-2301

EditRangeX


51/124



4.1.3 Select measuring unit

Unit selection is made using , . Press to

switch between mg/l and %. End by pressing .

4.1.4 Setting measuring span

Try to keep the measuring span as narrow as possible.

Specify the consistency values represented by output signals of 4 mA and

20 mA respectively.

Confi-gure

Tx.Spec

Unitxxx

Sendpage


---------------0% 53.3% 100%

Cons. 1.30% TCT-2301



Readdata

EditRangex

Confi-gure

Cali-brate

4 mA1.00%

20 mA3.00%

Damp1s

Offset0.00%

Misc. Print

Note ! Trend

Calib-rationcurve

Senddata4 mA

1.00% Tag: 25NT1237 Range 1---------------0% 53.3% 100%

Cons. 1.30% TCT-2301

20 mA3.00%


52/124

4.2 - Clear water adjustment


4.2 Clear water adjustment

4.2.1 At start up

A high-quality consistency measurement depends on a good zero refer-

ence value. The zero reference value is the signal when the probe is put

in Clear Water (CW).

! The water used for clear water adjustment must be of drinking

water quality.

The purpose of this adjustment is to establish the LED intensity setpoint

in water to have a zero reference when measuring in water.

It also provides a comparison value when cleaning the probe.

For LED intensity adjustment select .

The following menu appears, see fig 34. Then press

Fig 35 shows the following menu.

1. Fill a bucket of drinking water and put the probe in the water. Make

Confi-gure

Led int.adjust



Ledint.adjust

Tag

25NT1237

Tx.Spec

Mode

1

Menu

Devive TCT-2301 version 1.xxBoot version 1.xxDSP version xx

: Led intensity adjust-ment / basic sensitivity settings.

: Transmitter ID: Transmitter spec.

Fig 34 Configure sub-menu



CW/DCO

CW

LEDintens57.0%

SetCW96.7%

EditCW96.7%

Menu

Fig 35 LED int. adjust sub-

menu.

Sendpage

LED current: 54.1%

CW measured: 97.8%


53/124



sure that no air bubbles are trapped in the measuring gap on the

probe.

Remove any air bubbles with your fingers.

2. Make sure the transmitter is set for clear water, . If the key

is set on a dark signal adjustment will be made. This ad-

justment has been made in the factory and need not be repeated. The

dark signal adjustment is made using the plastic plug in the optical

connection instead of the probe.

3. Check that the CW measured value is 100% 5. If this is the case no

further action is needed, continue with 4.3.2. Otherwise continue

with point 4.

4. Change the LED intensity by pressing .

Change the LED intensity in steps by 2. Send the setting to the trans-

mitter by pressing and .

5. Check that the CW measured value is close to 100% (2%). If not,

repeat step 4.

6. When the CW measured value is stable press to store the

value. Send the setting to the transmitter by pressing

and .

7. Install the probe in the valve arrangement and lock it properly using

the two screws.

!Check that the measuring gap on the probe faces the flow at thecorrect angle. See section 3.2.5 for instruction on how to change

the angle.See section 4.2.3 for recommended angle settings

! The key Edit CW xx.x%is used to manually send a water value to

the transmitter if needed.

CW/DCO

CW

CW/DCO

DCO

LEDintens57.0%

Sendpage

Sendchange

SetCW96.7%

Sendpage

Sendchange

Changing the LEDintensity adjustmentchanges the setting of thetransmitter. This must bedone only when the probeis in clear water.


54/124



4.2.2 Selecting the correct mode

The TCT-2301 has preset calibration curves for different fiber types. Fi-

ber types are divided into two main groups, low-strength pulp (short fi-ber) and high-strength pulp (long fiber).

This setting is located under . See fig 34 on page 46.

Press the key to select the correct preset calibration curve de-

pending on the actual fiber type:

: This mode is for short-fiber pulps,

such as recycled and groundwood.

: This mode is for pulp types such as

kraft pulp, TMP, CTMP etc.

: This mode contains a linear curve

and is not normally used.

! Please contact BTG for further information on different pulp and

fiber types.

Confi-gure

Mode

1

Mode

1

Mode

2

Mode

3


55/124



4.2.3 Adjustment of measuring gap angle.

It is important that the measuring gap faces the flow at the correct angle.

Follow these guidelines.

Start with the standard setting, 45 facing the flow.

If the signal from the transmitter appears to be unstable despite using the

angles above, make the following quick test to see if can be improved.

Remove the probe from the line, see section 3.2.5:Mounting the probe

in the valve assembly, and adjust the angle in 15 increments. (15, 30,

45, 60, 75). Install the probe and observe the signal from the transmit-

ter.

! Contact BTG for further technical information.

! Never go under a 15 or over a 75 angle to the measuring gap. This

could spoil the cleaning effect of the measuring gap and/or createa plugging effect.


56/124



! Definition:

At 0 the measuring gap points directly towards the flow.At 90 the measuring gap points towards the pipe wall.

The transmitter is now ready for calibration against pulp samples.

Fig 36 Probe angles relative

to the measuring gap

Pulp Flow

Pulp Flow

Pulp Flow

Pulp Flow

Pulp Flow

Normal position


57/124

4.3 - Calibration


4.3 Calibration

This section assumes that you have completed section 4.2, and studied

the operation of the hand-held terminal as described in section 4.8.

4.3.1 General remarks on calibration

The transmitter should be calibrated for the specific application after it

has been installed in the line and all connections have been made.

The measuring principle used by this transmitter is insensitive to differ-

ent wood species and normally one calibration can be used with different

pulp/stock qualities.

The amount of filler can vary in different pulp/stock qualities and this canaffect the output signal. This can be handled by using different calibra-

tions (Measuring range).

4.3.1.1 Criteria for calibration

1. The transmitter is installed and has been started up.

2. A clear water adjustment must have been made as per section 4.2:

Clear water adjustment.

3. The hand-held terminal must be connected to the electronics box and

switched on, and the transmitter data read into the terminal as persection 4.1: Starting the transmitter.

4. The correct mode must be selected as per section 4.2.2: Selecting the

correct mode.

5. The pulp must have representative consistency and flow values.

4.3.2 General remarks on sampling

Additional information can be found in Accurate Consistency a

hand-book in consistency measurement in pulp and paper processing,

available from BTG.

To ensure acceptable precision in laboratory samples, we recommend use

of BTG sampling valves.



Readdata

EditRange1

Confi-gure

Cali-brate

4 mA0.50%

20 mA2.00%

Damp1s

Offset0.00%

Misc. Print

Note ! Trend

Calib-rationcurve

Senddata


---------------0% 53.3% 100%

Cons. 1.30% TCT-2301

Cali-brate

The only way to calibrate the transmitter correctly is to take

correct laboratory samples and adjust the transmitteraccordingly.


58/124

4.3 - Calibration


Sampling procedure:

1. Install the sampling valve close to the transmitter. The valve should

be installed so there is no interference from pipe bends, pumps, etc.

Recommendations regarding turbulence damping zones are the same

as for the transmitter itself.

2. Take at least two, preferably three, laboratory samples. Calculate the

mean value; reject samples that deviate widely from the mean.

Take an adequate volume for sampling at least 500 ml (1/2 US

quart) for a reliable sample.

3. Make sure that samples for calibration and subsequent checking are

always taken in the same manner regardless of who does the sam-

pling. Similarly, the laboratory procedure must always be exactly

the same.

The design of, and compliance with, sampling routines is crucial in as-

suring uniform treatment of samples. Calibration and future precision of

measurement by the transmitter depend on this.

During calibration, the pulp flow past the Transmitter must be represen-

tative for the position in which it is installed.

To simplify and improve the regular follow-up routines, the BTG Smart

lab sampler - SLS-1000 is a useful aid.

4.3.3 Calibration procedure

Normal calibration is very simple, only one sample needs to be taken.

The functionality of the TCT-2301 means that a single point calibration

or even the preprogrammed curve is often fully adequate.

Since only one sample is taken, it is very important that it is correct.

Therefore, take out a large sample so that several consistency determina-

tions can be made at the lab, and an average value can be downloaded to

the transmitter.

!It is important to read data to the SPC each time it is connected. Itis also important to continuously send all changes.

4.3.3.1 Summary

1. Collect values using the SPC at the same time as pulp samples are

taken from the line.

2. Evaluate the sample at the lab.

3. Enter the lab value in the SPC.

4. Calculate calibration constants.

5. Send the calibration values to the transmitter.


---------------0% 53.3% 100%

Cons. 1.30% TCT-2301

4-20mAMODEMPRINTER PWR EJECTON/OFF MEMORY CARD


Readdat

Piping Cons Controller

Documents

Transcript of Piping Cons Controller